ALUMINUM CONTENT IN

E U R O P E A N PA S S E N G E R C A R S

Prepared for

- Public Summary -
10.10.2019

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 TA B L E O F C O N T E N T

Assessment Scope 3
European Car Production 5
European Electric Vehicle Production 7
Aluminum Content in Cars 9
Aluminum Content by Vehicle Segment 11
Aluminum Content by Vehicle Brand 13
Aluminum Content by Vehicle Model 14
Aluminum Content by Component Group 15
Aluminum Content by Forming Process 19
Aluminum Content Evolution 2016-2028 20
Comparison of Aluminum Content by Powertrain Type 21

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ASSESSMENT SCOPE
This assessment of the Aluminum Content in European Passenger Cars encompasses all aluminum applications in a car,
includes electric vehicles, and is based on the analysis of a car sample covering nearly 95% of total EU28 production

Scope Deliverables
Application scope: Passenger cars CURRENT ALUMINUM CONTENT IN CARS1 (2019)
• Aluminium content by vehicle
Geographic scope: EU 28 (production location in EU 28 - CKD not  Component net weight (for components in focus)
included)  Forming process / Product form (sheet vs. extruded vs.
cast vs. forged)
Vehicle sample: accounts for 94.3% of total EU 28 production  Estimated additional aluminum content by vehicle
• Vehicle models have been jointly selected with EA (subcategories “Other”)
• 11 pure BEV models included in the sample:  [For engine blocks, cylinder heads and steering
knuckles only] Share of primary vs. secondary
⁻ BMW 3 Series EV aluminum
⁻ Mercedes Benz EQC
⁻ Mercedes Benz EQE Sedan • Average aluminium content per vehicle (after extrapolation to
⁻ Ford C EV whole EU28 production)
⁻ Peugeot 208 EV  Average component net weight (for components in
⁻ Renault Zoe ZE focus) by vehicle segment
⁻ Jaguar I-Pace  Average net weight of consolidated components in
⁻ Audi e-tron GT focus segmented by product form
⁻ Audi e-tron  Average additional aluminium content per component
⁻ Porsche Taycan group
⁻ Volkswagen ID.3 (previously called Neo)
ALUMINUM CONTENT FORECASTS (2025, 20282)
• Total
Product scope: aluminum components • By component group
• 11 components groups • By forming process
• 38 components in focus (see following page) • By component
[1] Total market exploration for conventional/hybrid-versions only; only selected EV
sample analyzed
[2] 2028 forecasts are modelled based on 2025 aluminum content data and projected

2028 vehicle production using same CAGR as from 2019 to 2025

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ASSESSMENT SCOPE
Aluminum applications are classified into 12 component groups. Within a component group, the focus has been set on
select main AL components; remaining applications have been considered in the each sub-category “Other”

Component Group Component Approach Component Group Component Approach

Blocks Research Transmission Case Research
Heads Research Differential Case Research
Head Covers Research Transmission Transfer Case Research
Engine Pistons Research Driveshaft Research
Powertrain Mounts Research Other Transmission Modelling
Oil Pans Research Complete Body Structures Research
Other Engine Modelling Shock Towers Research
Steering Research Rails Research
Suspension Arms Research Radiator Supports Research
Steering Knuckles (Front) Research Body Structure Structural Parts Research
Chassis & Suspension Wheel Carriers (Rear) Research IP Structures Research
Front & Rear Subframes Research Floor Group Research
Other Chassis & Suspension Modelling Body Side Panels Research
Wheels Research Other Body Structure Modelling
Brakes Research Hoods Research
External Trim Research Fenders Research
Roof Rails Research Liftgates, Decklids & Tailgates Research
Closures
Trim & Interior Interior Trims Modelling Front & Rear Doors Research
Sun roofs Modelling Roofs Research
Pans & Tracks Modelling Other Closures Modelling
Heat Exchangers Modelling Crash Management Bumpers & Crash Boxes Research
Heat Transfer Heat Shields Modelling Battery Boxes Research
Electrification
Other Heat Transfer Modelling Electric Motor Housing Research

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EUROPEAN CAR PRODUCTION
Car production forecasts expect steady growth, with a CAGR of 1.54% from 2019 to 2025.
The Volkswagen brand leads the European market, accounting alone for approx. 2 million cars produced in the EU28

10-year European Car Production 2016-2025 (EU 28)

(Million Units)
CAGR: 1.54% 18.3
18.0
17.8
17.7
17.4
17.2
17.0
16.9
16.8
16.7

2016 2017 2018 2019 2020 2021 2022 2023 2024 2025

2,000
Car Production by Brand 2016-2025 (EU 28)
(Thousand units)
1,500
2019 2025

1,000

500

Source: LMCA Database Q1 2019 + Ducker Frontier estimates

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EUROPEAN CAR PRODUCTION
C-Compact vehicles (e.g. VW Golf, Ford Focus, etc.) make up the majority of the car production (43%). Segment split
is expected to remain similar till 2025, though with stronger growth from B-segment and a decrease of A-segment

2019 Car Production by Segment Highest Production Programs by Segment

(2019, Thousand Units)

10% 6% Range Rover Sport

Audi Q7
A - BASIC Audi A6
15%
26% B - SUB-COMPACT BMW 5-Series
Mercedes-Benz E-Class
16.7M C - COMPACT
Volvo XC60
D - MIDSIZE
VW Passat
E - LARGE Mercedes-Benz GLC
Audi A4
43% BMW 3-Series

Peugeot 3008
VW Tiguan
2019 vs. 2025 Car Production by Segment Nissan Qashqai
(Million units) Ford Focus
VW Golf
1.86
1.68 Opel Corsa
2.74
2.47 Citroen C3
Dacia Duster
VW Polo
7.57 Ford Fiesta
7.12
Smart Fortwo
VW Up!
C3 Aircross
4.33 5.09
Fiat New Panda
Fiat 500
1.09 1.03
0 100 200 300 400 500
2019 2025

Source: LMCA Database Q1 2019 + Ducker Frontier estimates

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EUROPEAN ELECTRIC VEHICLE PRODUCTION
Electric vehicle production (BEV and PHEV combined) is expected to rapidly ramp-up, with a CAGR of over 30%
between 2019 and 2025

10-year EV Production (EU 28) – PHEV & BEV

Units

CAGR: 33.1%
3,324,607

14%
2,875,726

15%
2,407,040 21%

15%
1,969,863 21%

16% 21%
1,528,240

22% 42%
16%
1,085,810 40%
22%
19% 41%

597,420 23% 43%

383,927 46%
27% 20%
278,357 44% 19%
193,543 26% 24% 19%
26% 19% 33% 14%
38% 10% 11%
42% 35% 13% 5% 4% 4% 5% 4%
2016 2017 2018 2019 2020 2021 2022 2023 2024 2025

A - Basic B - Sub-Compact C - Compact D - Midsize E - Large

Source: LMCA Database Q1 2019 + Ducker Frontier estimates

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EUROPEAN ELECTRIC VEHICLE PRODUCTION
BEVs are forecasted to grow faster than PHEVs. C-segment will continue to be predominant. Smaller PHEVs will be
introduced (B-segment) and C-segment to gain shares

10-year BEV Production 2016-2025 (EU 28) 10-year PHEV Production 2016-2025 (EU 28)

2,277,199

1,047,408
CAGR: 42.6% CAGR: 21.4%

1,946,984

928,742
11%

810,106
1,596,934
20%

747,806
12% 18%

679,646
21%
1,222,057

594,553
18% 21%
12% 27%
21%
19% 23% 28%
848,594

13% 39%
25% 25%

326,902
37% 25%
21% 24%
491,257

11% 36%

201,437
24%

175,724
20%
270,518

49%
109,310
39% 40%
182,490

49% 46%
102,633

11% 27% 50%

42% 51%
84,233

21% 26%
27% 41% 48% 29% 49%
17% 38% 20% 34%
55% 37% 17% 36% 30%
56% 20% 7% 39% 30%
59% 30% 29% 10% 9% 7% 6% 6% 28% 23% 22% 4% 4% 4% 4%
2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025

A - Basic B - Sub-Compact C - Compact D - Midsize E - Large

Source: LMCA Database Q1 2019 + Ducker Frontier estimates

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ALUMINUM CONTENT IN CARS (2019)
Average Aluminum Content per Vehicle currently amounts to nearly 179kg and Total Aluminum Content for the whole
car market (including electric vehicles) is estimated at 2,989 KT – most of which being aluminum castings

Aluminum Content in Cars (2019)

Net weight

Average Al Content
Total Al Content
Per Vehicle

179.2 kg 2,989 KT

Cast 116.0 kg 1,936 KT

Sheet 34.0 kg 567 KT

Extrusions* 19.0 kg 317 KT

Forged 10.2 kg 169 KT

* Extrusions exclude forging stock

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ALUMINUM CONTENT IN CARS (2025)
Average AL Content per Vehicle is expected to increase by approx. 20kg to 198.8kg by 2025, bringing the Total AL
Content in European cars to 3,635 KT. AL casting is expected to remain the predominant forming process

Aluminum Content in Cars (2025)

Net weight

Average Al Content
Total Al Content
Per Vehicle

198.8 kg 3,635 KT

Cast 118.1 kg 2,161 KT

Sheet 43.2 kg 789 KT

Extrusions* 26.7 kg 489 KT

Forged 10.7 kg 196 KT

* Extrusions exclude forging stock

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ALUMINUM CONTENT BY VEHICLE SEGMENT
While E-segment vehicles have the highest Average AL Content per Vehicle (442kg), C-segment vehicles capture the
largest share (36%) of Total AL demand due to the overall volume of C-segment vehicle production

Total AL Content by Vehicle Segment (2019, Net Weight in KT) Average AL Content by Vehicle Segment (2019, Net Weight in kg)

442
E - LARGE;
742 A 3%
B 14%
E 25%
D - MIDSIZE;
656 266

152
C - COMPACT;
1,085 98
77
D 22% C 36%
B - SUB-COMPACT;
423 Total: 2,989 KT
A - BASIC; 84 A - BASIC B - SUB- C - COMPACT D - MIDSIZE E - LARGE
COMPACT

Vehicle Programs with the Highest Average AL Content (Net Weight 2019) per Segment

A - Basic B - Sub-Compact C - Compact D - Midsize E - Large

Opel Adam Audi Q2 BMW i3 Jaguar I-Pace Audi e-tron

2019 Production: ~27K units 2019 Production: ~82K units 2019 Production: ~40K units 2019 Production: ~21K units 2019 Production: ~29K units
Total AL Content 2019: 2.6 KT Total AL Content 2019: 12.5 KT Total AL Content 2019: 14.5 KT Total AL Content 2019: 15.0 KT Total AL Content 2019: 22.8 KT
Avg. AL Content 2019: 110kg Avg. AL Content 2019: 164kg Avg. AL Content 2019: 367kg Avg. AL Content 2019: 704kg Avg. AL Content 2019: 804kg

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ALUMINUM CONTENT BY VEHICLE SEGMENT
The Average AL Content per Vehicle is forecasted to increase by 19.6kg between 2019 to 2025 - only 2.9kg in A-
segment vehicles, but up to 38kg in D-segment vehicles. Growth will come from sheet and extrusions

Average Aluminum Content per Vehicle between 2019-2025 by Segment

Net Weight in kg
+22.2

464.2
442.1

+38.0

303.9
265.9
+19.6
+18.3
198.8
179.2 170.8
152.4 +13.1
+2.9
110.9
97.7
76.8 79.8

Avg. AL A B C D E Avg. AL A B C D E
Content Content
2019 2025

Average additional AL content per vehicle (kg) in 2025

+xx.x
as compared with 2019

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ALUMINUM CONTENT BY VEHICLE BRAND
However, on a per vehicle level, Jaguar Land Rover models have the highest aluminum content.
All premium brands are above market average, reversely all volume brands are below average

Average AL Content per Vehicle by Brand

2019, Net Weight in KG

Above Market Average Below Market Average

532

479

416
378

294
276 273 273 267

188 179
164
148 144
129 129 129 128 125 123 123 121
115 115 110 109
102 96 91 87
72

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ALUMINUM CONTENT BY VEHICLE MODEL
8 out of the 20 most aluminum-intensive vehicle models belong to the JLR group. The model with the highest AL
content however is the Audi e-tron with 804kg AL content (nearly 4.5 times the market average)

Top 20 Vehicle Models with the Highest Average AL Content per Vehicle
2019, Net Weight in kg

804 794
746
704
679
649 641 633
614 613 600 586
562 549 543 533 532 530 516 511

179

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ALUMINUM CONTENT BY COMPONENT GROUP
Engine and Wheels together represent almost half of Total Aluminum Content in cars (~45%)

Total Aluminum Content by Component Group

2019, Net Weight in KT

Electrification* 44
Other small parts 8 Engine
Trims & Interior 25 702
Brakes 52
Steering 61

Crash Management 74

Wheels
Body Structure 642
235 Total: 2,989 KT

Body Closures
200

Transmission
Heat Transfer
323
310
Chassis
314

*Electrification components includes Battery Box, Battery Cooling and Electric Motor Housing

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ALUMINUM CONTENT BY COMPONENT GROUP
Engine components and Wheels are by far the largest aluminum contributors. Average AL Content per Vehicle related
to Battery Box and Electric Motor Housing will grow fast with the expected accelerated production of EVs

2019 Average Aluminum Content per Vehicle by Component Group

Incl. all powertrain types, Net Weight in kg

TOTAL 179.2

Engine 42

Wheels 38

Transmission 19

Chassis 19

Heat Transfer + Battery Cooling 19

Body Closures 12

Body Structure 14

Crash Management 4

Steering 4

Brakes 3

Trims & Interior 2

Battery Box 1

Electric Motor Housing 1

Other small parts 2

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ALUMINUM CONTENT BY COMPONENT GROUP
Electrification components will be the main growth area by 2025, together with Body Closures.
Alone Battery Boxes account for nearly 2/3 of the Average AL Content increase to come

Avg. Aluminum Content Evolution 2016-2025 by Component Group

Net Weight in kg

+19.6 kg
+28.7 kg 198.8
179.2
3.3
3.1 3.7
3.6 4.5 Other small parts
4.4
150.5* 14.1 15.0 Trims & Interior
4.3 12.0 16.5 Brakes
2.9
3.8
8.1 Steering
18.6 17.6
10.4 Crash Management
16.9 18.8 Body Structure
19.8
Body Closures
15.6
19.4 18.8 Heat Transfer
17.8 Chassis
Transmission
38.5 39.3
27.0 Wheels
Engine

41.6 42.1 39.7

2016 2019 2025

* 2016 numbers do not include Electrification components (i.e. Battery Boxes, Battery Cooling and Electric Motor Housings), and are based on a limited sample of 60 vehicles that has been
extrapolated to the whole market. 2016 numbers do also not include the second set of OE wheels that is purchased at the same time as the vehicle

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ALUMINUM CONTENT BY COMPONENT GROUP
By 2025, Battery Box and Body Closures appear to be the component groups that will most benefit from the Average
Aluminum Content growth. On the contrary, aluminum demand for traditional powertrain components will decrease

Expected AL Gains & Losses within Average AL Content per Vehicle

For the time period 2019 to 2025 (Net Weight in kg)

Battery 179.2 kg +19.6 kg 198.8 kg

Box
12.38 2019 2025

Body
AL Gains

Closures
4.52 Electric
Motor
Housing Heat
2.69 Transfer
Body
+ Other
Chassis Structure Wheels Crash Battery small
0.98 0.97 0.79 Brakes Management Steering Cooling parts
0.17 0.09 0.02 0.01 0.00

Trims
AL Losses

& Transmission
Interior -0.58
-0.04
Engine
-2.43

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ALUMINUM CONTENT BY FORMING PROCESS
Cast aluminum represents the large majority of the Total Aluminum Content (in 2016, 2019 as well as in 2025).
Extrusions and Sheet will win shares by 2025, mainly driven by demand for Electrification components and Closures

Forming Process Split of Total AL Content (Net Weight in KT)

2019 Evolution 2016, 2019, 2025

11% 13%

11%

11%
19%
19%
Total: 18%
22%
2,989 KT
5% 66%
6% 65% 59%
6% 65%

5%

Innermost ring: 2016 (2,620 KT)

Middle Ring: 2019 (2,989 KT)
Cast Forged Sheet Extrusion Outer Ring: 2025 (3,635 KT)

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ALUMINUM CONTENT EVOLUTION (2016 -2028)
The evolution of Total AL Content is expected to continue on a positive trajectory, with further dynamic growth.
The 2028 demand is currently forecasted at approximately 4,160 KT (net weight)

Total Aluminum Content Evolution 2016-2028 (Net Weight in KT)

by Vehicle Segment

CAGR: 4.62%
4,163

CAGR: 3.31%
3,635

CAGR: 4.61%
2,989
E - Large
2,612 D - Midsize
C - Compact
B - Sub-Compact
A - Basic

2016 2019 2025 2028

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C O M PA R I S O N O F A L U M I N U M C O N T E N T B Y P O W E R T R A I N T Y P E
BEVs have significantly higher AL Content than their ICE variant, primarily due to the aluminum used for the Battery
Box. Overall, the higher the car segment, the larger the difference in AL Content between BEV and ICE variants

Avg. AL Content per Vehicle for ICE vs. BEV variant

2019, Net Weight kg

D-Midsize Vehicle from Premium Brand B-Sub-Compact Vehicle from Volume Brand
with ICV and BEV Variants with ICV and BEV Variants

+201.8

458.8

308.0

-51.0

+63.7
126.2
90.2

-27.7

ICV Powertrain AL AL Gains BEV ICV Powertrain AL AL Gains BEV

Losses Losses

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C O M PA R I S O N O F A L U M I N U M C O N T E N T B Y P O W E R T R A I N T Y P E
Large batteries for BEV & PHEV, as well as doubled powertrain components for PHEV, are strong drivers for high Average
Aluminum Content. Electric vehicle growth will foster a further increase of the Average Aluminum Content per Vehicle

Average Aluminum Content per Vehicle

Comparison by Powertrain Variant (2019, Net Weight in kg)

+39.7kg
360.5

+141.6kg
320.8

+7.1kg
179.2
172.1

ICV Overall BEV PHEV

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 T H A N K YO U
This concludes our presentation. Today’s presentation was prepared by
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